Water heater appliance

ABSTRACT

A water heater appliance defining a vertical direction includes a tank for holding water. The water heater appliance further includes a shroud and a fan. The shroud may be positioned at a top portion of the tank. In addition, the shroud may define a chamber positioned over the tank along the vertical direction, and the shroud may further define a vent assembly extending through the shroud from the chamber of the shroud. The fan may be positioned within the chamber. In addition, the fan may include a hub and a plurality of blades extending from the hub. The plurality of fan blades may be rotatable in a first direction. Further, each of the plurality of blades may be positioned and oriented on the hub such that the fan discharges air in a direction that is substantially tangential to the first direction.

FIELD OF THE INVENTION

The present subject matter relates generally to heat pump water heaterappliances.

BACKGROUND OF THE INVENTION

Heat pump water heaters are gaining broader acceptance as a moreeconomic and ecologically-friendly alternative to electric waterheaters. These systems utilize a condenser configured in a heat exchangerelationship with a water storage tank, for example wrapped around thetank in a series of coils. During operation of the vapor compressionheat pump cycle, air flows across an evaporator and transfers energy toa refrigerant flowing through the evaporator. As such, the refrigerantexits the evaporator as a superheated vapor and/or high quality vapormixture. Upon exiting the evaporator, the refrigerant enters acompressor where the pressure and temperature increase and therefrigerant becomes a superheated vapor. The superheated vapor from thecompressor then enters the condenser, wherein the superheated vaportransfers energy to the water within a storage tank and returns to asaturated liquid and/or high quality liquid vapor mixture.

Certain heat pump water heaters include a shroud positioned over thestorage tank. Various components of the heat pump water heater, such asthe compressor, evaporator, and a fan, are disposed within the shroud.The fan generally circulates air directly out toward a back of theshroud. Thus, heat pump water heaters are preferably spaced apart fromwalls and other similar barriers to ensure proper airflow through theshroud. This diminishes the amount of usable space within a room or areain which a heat pump water heater is located, which is undesirable. Inaddition, the spacing between a heat pump water heater and a wall makesit difficult to secure the heat pump water heater to the wall, whichcertain localities require to prevent inadvertent movement of the heatpump water heater during an earthquake.

Accordingly, a heat pump water heater appliance with features forimproving airflow would be beneficial. More specifically, a heat pumpwater heater appliance having improved airflow that reduces the amountof space consumed by the water heater appliance would be welcomed.

BRIEF DESCRIPTION OF THE INVENTION

The present disclosure provides a water heater appliance. The waterheater appliance includes a fan positioned within a chamber of the waterheater appliance. The fan can rotate in a first direction and direct airin a direction that is substantially tangential to the first direction.Additional aspects and advantages of the invention will be set forth inpart in the following description, or may be apparent from thedescription, or may be learned through practice of the invention.

In a first exemplary embodiment, a water heater appliance defining avertical direction includes a tank for holding water. The water heaterappliance further includes a shroud and a fan. The shroud may bepositioned at a top portion of the tank. In addition, the shroud maydefine a chamber positioned over the tank along the vertical direction,and the shroud may further define a vent assembly extending through theshroud from the chamber of the shroud. The fan may be positioned withinthe chamber. In addition, the fan may include a hub and a plurality ofblades extending from the hub. The plurality of fan blades may berotatable in a first direction. Further, each of the plurality of bladesmay be positioned and oriented on the hub such that the fan dischargesair in a direction that is substantially tangential to the firstdirection.

In a second exemplary embodiment, a water heater appliance defining avertical direction includes a tank for holding water. The water heaterappliance further includes a shroud, an evaporator, and a fan. Theshroud may be positioned at a top portion of the tank. In addition, theshroud may define a chamber positioned over the tank along the verticaldirection, and the shroud may further define a first vent and a secondvent both extending through the shroud from the chamber of the shroud.Further, the first vent may be defined at a top wall of the shroud, andthe second vent may be defined at a side wall of the shroud. Theevaporator and fan may both be positioned within the chamber. Inaddition, the fan may include a hub and a plurality of blades extendingfrom the hub. The plurality of fan blades may be rotatable in a firstdirection. Further, each of the plurality of blades may be positionedand oriented on the hub such that the fan discharges air in a directionthat is substantially tangential to the first direction.

These and other features, aspects and advantages of the presentinvention will become better understood with reference to the followingdescription and appended claims. The accompanying drawings, which areincorporated in and constitute a part of this specification, illustrateembodiments of the invention and, together with the description, serveto explain the principles of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

A full and enabling disclosure of the present invention, including thebest mode thereof, directed to one of ordinary skill in the art, is setforth in the specification, which makes reference to the appendedfigures.

FIG. 1 provides a front elevation view of a water heater applianceaccording to an exemplary embodiment of the present disclosure;

FIG. 2 provides a perspective elevation view of the exemplary waterheater appliance of FIG. 1;

FIG. 3 provides a front section view of the exemplary water heaterappliance of FIG. 1;

FIG. 4 provides an elevated view of a chamber positioned over a tank ofthe exemplary water heater appliance of FIG. 1;

FIG. 5 provides a perspective view of a fan according to an exemplaryembodiment of the present disclosure;

FIG. 6 provides a back view of the exemplary fan of FIG. 5;

FIG. 7 provides a cross-sectional view of a fan blade of the exemplaryfan of FIG. 5; and

FIG. 8 provides a top down view of the of the exemplary fan of FIG. 5;and

FIG. 9 provides a cross-sectional side view of the exemplary fan of FIG.5.

DETAILED DESCRIPTION

Reference now will be made in detail to embodiments of the invention,one or more examples of which are illustrated in the drawings. Eachexample is provided by way of explanation of the invention, notlimitation of the invention. In fact, it will be apparent to thoseskilled in the art that various modifications and variations can be madein the present invention without departing from the scope or spirit ofthe invention. For instance, features illustrated or described as partof one embodiment can be used with another embodiment to yield a stillfurther embodiment. Thus, it is intended that the present inventioncovers such modifications and variations as come within the scope of theappended claims and their equivalents.

FIG. 1 provides a front elevation view of a water heater appliance 100according to an exemplary embodiment of the present disclosure. Thewater heater appliance 100 defines a vertical direction V, and the waterheater appliance 100 extends longitudinally between a top portion 102and a bottom portion 104 along the vertical direction V. The waterheater appliance 100 includes an outer shell or casing 106. The casing106 generally surrounds a tank 108 (FIG. 2) such that the tank 108 isdisposed within the casing 106. The tank 108 includes a top portion 110and a bottom portion 112 spaced apart from one another along thevertical direction V. In addition, the tank defines an interior volume114 extending between the top portion 110 and the bottom portion 112along the vertical direction V.

The casing 106 may be formed from a variety of components. Asillustrated, the casing 106 may include a wrapper 116, one or morecovers, such as a top cover 118 and a bottom cover 120, and a shroud 122as illustrated. The shroud 122 may be positioned at the top portion 110of the tank 108 along the vertical direction V such that the shroud 122defines a chamber 124 (FIG. 3) positioned over the tank 108 along thevertical direction V. Additionally, the shroud 122 may define a ventassembly comprising a first vent 126 (FIG. 4) and a second vent 128(FIG. 3) that each extend through the shroud 122 from or to the chamber124 of the shroud 122.

Upper and lower heating elements 130, 132 (FIG. 2) and a sealed system134 (FIG. 2) may also be positioned within the casing 106 for heatingwater within the tank 108. The upper and lower heating elements 130, 132can be any suitable heating elements. For example, the upper heatingelement 130 and/or lower heating element 132 may be an electricresistance element, a microwave element, an induction element, or anyother suitable heating element or combination thereof. The lower heatingelement 132 may also be a gas burner. As will be understood by thoseskilled in the art and as used herein, the term “water” includespurified water and solutions or mixtures containing water and, e.g.,elements (such as calcium, chlorine, and fluorine), salts, bacteria,nitrates, organics, and other chemical compounds or substances.

The water heater appliance 100 also includes an inlet or cold waterconduit 136 and an outlet or hot water conduit 138 that are both influid communication with a chamber or interior volume 114 (FIG. 2)defined by the tank 108. As an example, cold water from a water source,e.g., a municipal water supply or a well, can enter the water heaterappliance 100 through the cold water conduit 136. From the cold waterconduit 136, such cold water can enter the interior volume 114 of thetank 108 wherein the water is heated with heating elements 130, 132and/or sealed system 134 to generate heated water. Such heated water canexit the water heater appliance 100 at the hot water conduit 138 and,e.g., may be supplied to a bath, shower, sink, or any other suitablefeature.

As mentioned above, the water heater appliance 100 extendslongitudinally between the top portion 102 and the bottom portion 104along the vertical direction V. Thus, the water heater appliance 100 isgenerally vertically oriented. The water heater appliance 100 can beleveled, e.g., such that the casing 106 is plumb in the verticaldirection V, in order to facilitate proper operation of the water heaterappliance 100. It should be understood that the water heater appliance100 is provided by way of example only and that the present subjectmatter may be used with any suitable water heater appliance, includingfor example any heat pump water heater appliance.

FIG. 2 provides a front section view of the water heater appliance 100.As may be seen in FIG. 2, the water heater appliance 100 includes thesealed system 134 for heating water within the interior volume 114 ofthe tank 108. The sealed system 134 generally operates in a heat pumpcycle. Thus, the water heater appliance 100 is commonly referred to as a“heat pump water heater appliance.” The water heater appliance 100 mayadditionally include one or more auxiliary heating elements, such as theupper heating element 130 and/or the lower heating element 132.

The sealed system 134 may include a compressor 140, a condenser 142 andan evaporator 144. The compressor 140 and/or evaporator 144 of thesealed system 134 may be disposed within the casing 106 at the topportion 102 of the water heater appliance 100, e.g., within the shroud122. As is generally understood, various conduits may be utilized toflow refrigerant between the various components of the sealed system128. Thus, e.g., the evaporator 144 may be between and in fluidcommunication with the condenser 142 and the compressor 140. Duringoperation of the sealed system 134, refrigerant may flow from theevaporator 144 through the compressor 140. For example, refrigerant mayexit the evaporator 144 as a fluid in the form of a superheated vaporand/or high quality vapor mixture. Upon exiting the evaporator 144, therefrigerant may enter the compressor 140. The compressor 140 may beoperable to compress the refrigerant. Accordingly, the pressure andtemperature of the refrigerant may be increased in the compressor 140such that the refrigerant becomes a superheated vapor.

The condenser 142 may be assembled in a heat exchange relationship withthe tank 108 in order to heat water within the interior volume 114 ofthe tank 108 during operation of the sealed system 134. In particular,the condenser 142 may be positioned downstream of and in fluidcommunication with the compressor 140, and may be operable to heat thewater within the interior volume 114 using energy from the refrigerant.For example, the superheated vapor from the compressor 140 may enter thecondenser 142 wherein it transfers energy to the water within the tank108 and condenses into a saturated liquid and/or liquid vapor mixture.

The sealed system 134 may also include a throttling device 146 betweenthe condenser 142 and the evaporator 144. Refrigerant, which may be inthe form of high quality/saturated liquid vapor mixture, may exit thecondenser 142 and travel through the throttling device 146 beforeflowing through the evaporator 144. The throttling device 146 maygenerally expand the refrigerant, lowering the pressure and temperaturethereof. The refrigerant may then be flowed through the evaporator 144.

The throttling device 146 may be any suitable components for generallyexpanding the refrigerant. For example, in some exemplary embodiments,the throttling device 146 may be a Joule-Thomson expansion valve, alsoknown as a “J-T valve.” In other exemplary embodiments, throttlingdevice 146 may be an ejector. In still other exemplary embodiments, acapillary tube, fixed orifice, or other suitable apparatus may beutilized as throttling device 146.

The water heater appliance 100 may additionally include a temperaturesensor 148. The temperature sensor 148 may be configured for measuring atemperature of water within the interior volume 114 of the tank 108. Thetemperature sensor 148 can be positioned at any suitable location withinthe water heater appliance 100. For example, the temperature sensor 148may be positioned within the interior volume 114 of the tank 108 or maybe mounted to the tank 108 outside of the interior volume 114 of thetank 108. The temperature sensor 148 may further be positioned within anupper portion of the tank 108. Alternatively, the temperature sensor 148may be positioned within a lower portion of the tank 108. When mountedto the tank 108 outside of the interior volume 114 of the tank 108, thetemperature sensor 148 can be configured for indirectly measuring thetemperature of water within the interior volume 114 of the tank 108. Forexample, the temperature sensor 148 can measure the temperature of thetank 108 and correlate the temperature of the tank 108 to thetemperature of water within the interior volume 114 of the tank 108. Thetemperature sensor 148 may be any suitable temperature sensor. Forexample, the temperature sensor 148 may be a thermocouple or athermistor.

The water heater appliance 100 may further include a controller 150 thatregulates operation of the water heater appliance 100. The controller150 may be, for example, in operative communication with the sealedsystem 128 (such as compressor 122, and/or other components thereof),auxiliary heating elements, and/or temperature sensor 144. Thus, thecontroller 150 can selectively activate the sealed system 128 and/orauxiliary heating elements in order to heat water within interior volume114 of tank 108.

The controller 150 includes memory and one or more processing devicessuch as microprocessors, CPUs or the like, such as general or specialpurpose microprocessors operable to execute programming instructions ormicro-control code associated with operation of water heater appliance100. The memory can represent random access memory such as DRAM, or readonly memory such as ROM or FLASH. The processor executes programminginstructions stored in the memory. The memory can be a separatecomponent from the processor or can be included onboard within theprocessor. Alternatively, the controller 150 may be constructed withoutusing a microprocessor, e.g., using a combination of discrete analogand/or digital logic circuitry (such as switches, amplifiers,integrators, comparators, flip-flops, AND gates, and the like) toperform control functionality instead of relying upon software.

Referring now to FIGS. 3 and 4, the sealed system 134 includes a fan 160disposed within the chamber 124. More specifically, the fan 160 ispositioned between the evaporator 144 and the second vent 128. Inoperation, the fan 160 draws air into the chamber 124 through the firstvent 126. More specifically, the fan 160 draws the air across theevaporator 144 to cool the evaporator 144. Further, the fan 160 maydirect the air out of the chamber 124 through the second vent 128.

The first vent 126 may be positioned above the compressor 140 along thevertical direction V. Further, the first vent 126 may be positionedproximate to the controller 150 at a front portion of the shroud 122.More specifically, the first vent 126 may be defined at a top wall ofthe shroud 122. The second vent 126 may be positioned between the firstvent 126 and the controller 150 along the vertical direction V. Further,the second vent 128 may be spaced apart from the compressor 140 along aradial direction R. More specifically, the second vent 128 may bepositioned proximate to a rear portion of the shroud 122. In oneexemplary embodiment, the second vent 128 may be defined at a side wallof the shroud 122, wherein the side wall extends downwardly from the topwall of the shroud 122 along the vertical direction V.

FIGS. 5 through 9 depict an exemplary embodiment of the fan 160 inaccordance with the present disclosure. The fan 160 defines a coordinatesystem comprising an axial direction A, a circumferential direction C,and a radial direction R. The fan 160 includes a hub 162, a plurality offan blades 164, and a casing 166. The hub 162 extends along the axialdirection A, and the casing 166 is spaced apart from hub 162 along theradial direction R. More specifically, the casing 166 surrounds the hub162 along the circumferential direction C. Each of the plurality of fanblades 164 extends between the hub 162 and the casing 166 along theradial direction R. As such, each blade of the plurality of blades 164defines a span along the radial direction R. Further, each of theplurality of fan blades 164 are spaced apart from one another along thecircumferential direction C. More specifically, in one exemplaryembodiment, a blade root of each fan blade 164 may be attached to thehub 162, and a blade tip of each fan blade 164 may be attached to thecasing 166. Thus, the plurality of fan blades 164, specifically theblade tip of each fan blade 164, may not vibrate during rotation.Alternatively, or in addition to, the plurality of fan blades 164 areeach spaced substantially equidistant from one another along thecircumferential direction C.

The fan 160 may also include a motor (not shown), such as an electricmotor, having an output shaft. The hub 162 may define an aperture sizedto receive the output shaft. In operation, the motor may rotate theshaft and hub 162. In one exemplary embodiment, the hub 162, pluralityof fan blades 164, and casing 166 may be integrally formed with oneanother. For example, the hub 162, plurality of fan blades 164, andcasing 166 may be formed of or with a single, seamless piece ofinjection molded material. Thus, in such an embodiment, the motor mayrotate the hub 162, plurality of fan blades 164, and casing 166 via theoutput shaft. More specifically, each of the plurality of fan blades 164may be swept forward in a first direction 170, e.g., in the direction ofrotation of fan 160. It should be appreciated, however, that the motormay be configured to rotate the shaft in a clockwise manner or acounterclockwise manner. Thus, the first direction 170 may correspond toeither the clockwise direction or the counterclockwise direction.

FIG. 6 provides a back view of the fan 160. In particular, the pluralityof fan blades 164 may each define a leading edge 168 and a trailing edge169. Specifically, the leading edge 168 and trailing edge 169 may bespaced apart from one another along the circumferential direction C. Asshown in FIG. 6, the trailing edge 169 trails the leading edge 168 whenthe plurality of blades 164 are swept in the first direction 170. Inaddition, the plurality of fan blades 164 may each define a chord 172(FIG. 7) that extends between the leading edge 168 and the trailing edge169.

The chord 172 defines a pitch angle β relative to the axial direction A.In the embodiment shown in FIG. 7, the trailing edge 169 is positionedabove the leading edge 168 along the radial direction R. In analternative embodiment, the trailing edge 169 is positioned below theleading edge 168 along the radial direction R. It should be appreciatedthat the pitch angle β includes any suitable range of angles. Forexample, the pitch angle β may be between seven (7) and fifteen (15)degrees.

The plurality of fan blades 164 may each also define a first width W1and a second width W2. The first width W1 may be defined at or adjacentthe hub 162, and the second width W2 may be defined at or adjacent thecasing 166. Further, the first width W1 may be different than the secondwidth W2. For example, in one embodiment, the first width W1 may be lessthan the second width W2. Specifically, the second width W2 may be noless than twice the first width W1.

When the fan 160 is rotating in the first direction 170, the pluralityof fan blades 164 may draw air 180 into an air path defined between thecasing 166 and the hub 162 along the radial direction R. Further, theplurality of fan blades 164 may each be positioned and oriented on thehub 162 such that each of the plurality of fan blades 164 discharges air182 in a direction that is substantially tangential to the firstdirection 170. More specifically, the direction of the discharge air maybe substantially tangential to the first direction 170 in a plane thatis substantially perpendicular to the axial direction A. For example, inone exemplary embodiment, the fan 160 may discharge air 182 at an angleθ greater than about forty-five (45) degrees relative to the axialdirection A. More specifically, the fan 160 may discharge air 182 at anangle greater than about forty-five (45) degrees but no greater thanabout sixty (60) degrees relative to the axial direction A. As usedherein, the term “about” means within ten percent (10%) of the statedangle when used in the context of angles. As shown in FIG. 9, the hub162 defines a length L along the axial direction A. In some embodiments,the length L of the hub 162 is less than the span of each of theplurality of blades 164.

In general, the exemplary embodiment of the fan 160 described hereinimproves airflow within the shroud 122. Specifically, the orientationand position of the plurality of blades 164 on the hub 162 reduce oreliminate the amount of discharged air that flows directly out a back ofthe shroud relative to known heat pump water heaters. Accordingly, heatpump water heater appliances with the fan 160 can be placed closer towall or other barriers and will consume less space in an associated roomor area relative to known heat pump water heaters. In addition, heatpump water heater appliances with the fan 160 will not require the useof an auxiliary duct to redirect air emitted from the second vent 128.

This written description uses examples to disclose the invention,including the best mode, and also to enable any person skilled in theart to practice the invention, including making and using any devices orsystems and performing any incorporated methods. The patentable scope ofthe invention is defined by the claims, and may include other examplesthat occur to those skilled in the art. Such other examples are intendedto be within the scope of the claims if they include structural elementsthat do not differ from the literal language of the claims, or if theyinclude equivalent structural elements with insubstantial differencesfrom the literal languages of the claims.

What is claimed is:
 1. A water heater appliance defining a verticaldirection, the water heater appliance comprising: a tank for holdingwater; a shroud positioned at a top portion of the tank, the shrouddefining a chamber positioned over the tank along the verticaldirection, the shroud further defining a vent assembly extending throughthe shroud from the chamber of the shroud; and a fan positioned withinthe chamber, the fan comprising a hub and a plurality of bladesextending from the hub, the plurality of blades rotatable in a firstdirection, wherein each of the plurality of blades is positioned andoriented on the hub such that the fan discharges air in a direction thatis substantially tangential to the first direction.
 2. The water heaterappliance of claim 1, wherein the vent assembly includes a first ventand a second vent, the first vent defined at a top wall of the shroud,the second vent defined at a side wall of the shroud.
 3. The waterheater appliance of claim 2, wherein the fan is positioned adjacent thesecond vent such that discharged air from the fan exits the chamberthrough the second vent.
 4. The water heater appliance of claim 2,wherein the fan is positioned between the second vent and an evaporatorpositioned within the chamber.
 5. The water heater appliance of claim 1,wherein the fan further comprises a casing surrounding the fan blades.6. The water heater appliance of claim 5, wherein the hub, the pluralityof blades and the casing are integrally formed with one another suchthat all of the hub, the plurality of blades and the casing arerotatable in the first direction.
 7. The water heater appliance of claim5, wherein each of the plurality of blades define a pitch angle betweenseven degrees and eighteen degrees.
 8. The water heater appliance ofclaim 5, wherein each blade of the plurality of blades is swept forwardin the first direction.
 9. The water heater appliance of claim 8,wherein each blade of the plurality of blades is swept such that eachblade of the plurality of blades defines a leading edge and a trailingedge, the leading edge of each blade of the plurality of blades has acommon chord with a respective trailing edge.
 10. The water heaterappliance of claim 1, wherein each blade of the plurality of blades hasa first width at the hub and a second width at the casing, the secondwidth being no less than twice the first width.
 11. The water heaterappliance of claim 1, wherein the hub has a length along an axialdirection of the fan, and each blade of the plurality of blades definesa span along a radial direction of the fan, the length of the hub beingless than the span of each of the plurality of blades.
 12. A waterheater appliance defining a vertical direction, the water heaterappliance comprising: a tank for holding water; a shroud positioned at atop portion of the tank, the shroud defining a chamber positioned overthe tank along the vertical direction, the shroud further defining afirst vent and a second vent extending through the shroud from thechamber of the shroud; an evaporator positioned within the chamber; afan positioned within the chamber, the fan comprising a hub and aplurality of blades extending from the hub, the plurality of bladesrotatable in a first direction, wherein each of the plurality of bladesis positioned and oriented on the hub such that the fan discharges airin a direction that is substantially tangential to the first direction,wherein the first vent is defined at a top wall of the shroud and thesecond vent is defined at a side wall of the shroud.
 13. The waterheater appliance of claim 12, wherein the fan further comprises a casingsurrounding the fan blades.
 14. The water heater of appliance of claim13, wherein the hub, the plurality of blades and the casing areintegrally formed with one another such that all of the hub, theplurality of blades and the casing are rotatable in the first direction.15. The water heater appliance of claim 13, wherein each of theplurality of blades defines a pitch angle between seven and fifteendegrees.
 16. The water heater appliance of claim 13, where each blade ofthe plurality of blades has a first width at the hub and a second widthat the casing, the second width being no less than twice the firstwidth.
 17. The water heater appliance of claim 12, wherein each of theplurality of blades are spaced substantially equidistant from oneanother.
 18. The water heater appliance of claim 12, wherein the hub hasa length along an axial direction of the fan, and each blade of theplurality of blades defines a span along a radial direction of the fan,the length of the hub being less than the span of each of the pluralityof blades.